Three dimensional insert construction

ABSTRACT

A three-dimensional insert for use in a handling system comprising a sheet of cardstock or the like defined by ends and first and second sides, a laminate applied to the top surface of the cardstock, and an overwrap material bonded to the laminate proximate to the first and second sides. This structure enables a three-dimensional object to be placed within the overwrap material without risk of movement to the peripheral sides.

This application is a continuation-in-part of co-pending applicationSer. No. 8/742,785, filed Oct. 31, 1996, abandoned.

FIELD OF THE INVENTION

The present invention generally relates to the packaging art, and moreparticularly, to a three-dimensional insert construction provided in acontinuous web of inserts that may readily be handled by automatedpackaging equipment or the like.

BACKGROUND OF THE INVENTION

Packaging apparatus particularly adapted for handling inserts or couponsprovided in the continuous web are known in the art from, for example,Kotsiopoulos' U.S. Pat. No. 5,079,901, assigned to the assignee of thepresent invention. This document describes an apparatus and system thatreceives a continuous web of coupons, provides a forwardmost couponbetween pairs of feed rolls and burst rolls, and at a desired time,separates the forwardmost coupon from the continuous web by applying abursting tension to a transverse perforation separating the forwardmostcoupon from the next succeeding coupon. The separated coupon is thenpassed to a point of insertion at a desired time such as into a movingcontainer based on signals provided by timing circuitry.

Other insertion handling apparatus are known such as that described inClauser's U.S. Pat. No. 5,549,233. This patent describes an inserthandling system that processes three-dimensional piece inserts with theuse of laterally-spaced pairs of rolls. This configuration enables thethree-dimensional aspect of the insert to be “passed through” thehandling; apparatus intermediate to the spaced sets of rolls. However,problems may occur with these equipment types where the projected pieceinsert requires a flat area to be used to drive the piece either forbursting or for projection of an individual piece into a container orthe like.

One attempt to overcome this problem has been to provide an insert thatutilizes a piece of rigid cardstock or the like together with athree-dimensional item. The additional rigidity provided by thecardstock adds desired stiffness to the insert. However, it does notovercome the problem of the packet or prize being laterally displaced tothe peripheral sides of the cardstock during storage or handling andinterfering with the rollers utilized in the burst operation. This isparticularly problematic when a relatively high throughput of inserts isrequired, requiring frequent stoppages of the processing line. Otherapproaches have included the use of glue applied to the cardstock tosecure the object in a desired location on the cardstock and/or theobject. While this approach solves the problem of lateral movement ofthe three-dimensional object, it dramatically increases themanufacturing cost of the insert. In addition, proper alignment of theobject with the glued portion of the cardstock is often problematic. Theresidual glue on the object may also by undesirable to the end user.

Yet another approach is referred to as “skin pack,” in which plasticfilm is attached to a porous paper backer material through which avacuum is drawn to conform the film to the item to be packaged. Althoughthis method also solves the problem of lateral movement, the porouspaper backer is, inherently, not well suited for most permeabilityrequirements of food-contact inserts.

SUMMARY OF THE INVENTION

Accordingly, it is a general object of the invention to overcome thedeficiencies of the prior art.

It is a further object of the present invention to provide athree-dimensional insert which is easily fabricated at acceptable cost,while enabling ready handling in a coupon-handling system.

The present invention provides these and other additional objects with athree-dimensional insert comprising a piece of cardstock or paperboarddefined by first and second opposed ends. A thermosealable, olefincoating or film is applied to the top surface of the board. An overwrapmaterial is contacted with the coating and is bonded therewith toprovide a seal between the overwrap material and the laminate surface ofthe card. This arrangement presents relatively consistent surfaces thatare readily grasped by coupon processing equipment. In this way, a prizeor other three-dimensional object is retained in the overwrap withoutmoving toward the peripheral sides utilized in handling the insert.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of first and second inserts provided in acontinuous web of inserts according to the present invention;

FIG. 2 illustrates a piece of cardstock laminated with an adhesivematerial on two peripheral edges of the cardstock; and

FIG. 3 is a sectional view of the insert shown in FIG. 1 taken along thelines 3—3.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Generally, the present invention relates to an insert used in apackaging application. The insert is particularly suited for handling byautomated processing equipment such as that disclosed in U.S. Pat. No.5,549,233, the subject matter of which is incorporated herein byreference. Such equipment is adapted to engage the peripheral side edgesof the insert while a three-dimensional object located in the centralportion of the insert passes between the sets of rolls to enablehandling of various types of three-dimensional objects. By way ofexample, the three-dimensional object may be a premium, prize or apackage component that is intended to be inserted into a container suchas a cereal lox, bag or pouch. Alternatively, the insert may be a packetof flavoring or seasoning that is intended to be placed into acontainer, while remaining physically separated from the remainingcontents of the container.

FIG. 1 is an isometric view of first and second inserts or coupons 10,12 provided in a continuous web or stream of inserts. In the preferredembodiment, each of the inserts 10, 12 includes a three-dimensionalpiece or object 10p, 12p while will ultimately be placed within acontainer or the like. By way of example, the objects 10p, 12p may beprizes or the like provided in cereal boxes, bread wrappers or othersuitable containers. Alternatively, the pieces 10p, 12p may be smallpackages which are utilized in food packaging or other similarapplications.

The inserts 10, 12 are preferably provided in a continuous web formatand are separated from each other by a perforation 14 disposed to extendtransversely to the web which connects inserts 10, 12 together. Theremaining inserts in the web are similarly connected to each other.

FIG. 2 illustrates a relatively flat piece 20 of cardstock, paperboardor other material having a suitable rigidity to withstand processing byautomated handling equipment. In this way, the cardstock piece providesstructural support for the insert. The cardstock piece is defined by apair of ends 20e, a pair of opposed sides 20s, and a top surface. FIG. 2also shows the cardstock piece 20 having a thermosealable laminate 22applied to the entire top surface of the cardstock. Preferably, thelaminate 22 is an olefin-based polyethylene material or other materialhaving suitable thermo-sealing characteristics.

Alternatively, a pair of laminate adhesive strips (not shown) may beapplied to the peripheral edges of the cardstock piece 20, preferablyproximate to the sides 20s. In this embodiment, the card 20 may belaminated with a heat sealable polyethylene material strips that extendthe lengthwise dimension of the piece 20 between ends 20e. It shouldalso be understood that the laminate adhesive may be applied to the topsurface of the cardstock piece in other forms, such as in the form ofspaced lands or the like.

The cardstock piece 20 with thermo-sealable laminated and object 10p aresurrounded by a plastic overwrap material such as overwrap material 26.For example, the overwrap material may be utilized to circumscribe theobject and cardstock 20 to provide a barrier with the outside such as anaseptically packaged insert. Preferably, the overwrap material ends 26eare heat sealed together to provide a transverse band which is thenperforated or otherwise weakened proximate to the ends 20e of thecardstock. The sides 26s of the overwrap material are also preferablyheat sealed or otherwise bonded to affixed to the lateral sides of thelaminate surface 22 to completely enclose the three-dimensional object.One alternative method for engaging the overwrap material with thelateral sides of the laminate surface 22 is with the use of rollers orthe like which provides a suitable compressive forces to the overwrapmaterial and laminate to provide a seal therebetween. In any event, aseal is provided between the overwrap material and the thermo-sealablelaminate surface of the cardstock at locations proximate to the sideedges of the cardstock piece. In the preferred embodiment, the overwrapmaterial is fabricated of the same material as the laminate, for examplean olefin-based material. However, the overwrap may be fabricated of adifferent material so long as its bonding characteristics are such thatit will be readily secured with the laminate surface 22 upon theapplication of heat and/or compressive forces applied to the lateraledges of the cardstock piece.

Accordingly, the three-dimensional object such as a promotional piece orpacket is prevented from being laterally moved or dislodged toward theperipheral side edges of the insert and is kept away from the handlingequipment. In addition, this arrangement presents relatively flat,uniform side surfaces which are the portions of the insert to be handledby the processing equipment.

As described in said U.S. Pat. No. 5,549,233, the web of inserts ispresented to handling apparatus which engages the sides of the insert.In this regard, spaced pairs of feed rolls engage the side edges of theforwardmost insert in the web and pass the coupon downstream to apre-dispense location, preferably such that the forwardmost coupon isengaged by spaced pairs of burst rolls while the perforation separatingthe forwardmost coupon is disposed between the pairs of feed rolls andthe burst rolls. At the desired time, the burst rolls are rotated atrelative angular speed greater than that of the feed rolls to apply abursting tension to the perforation between the forwardmost coupon andthe next succeeding coupon to disengage the forwardmost coupon from theremainder of the web and to position the coupon into a container or thelike. In this way, three-dimensional inserts of the type described abovemay be readily placed into containers.

Accordingly, a three-dimensional insert meeting the aforestatedobjectives has been described. The insert provides improved structuralintegrity as well as improved handle-ability. While the invention hasbeen described in terms of the best mode currently contemplated, thoseskilled in the art will appreciate that various modifications may bemade without departing from the spirit and scope of the invention, asdefined by the appended claims.

What is claimed is:
 1. An insert adapted for use in conjunction withpackaging apparatus comprising: a three-dimensional object; a piece ofcardstock including a top surface defined by first and second ends andfirst and second side edges; thermo-sealable laminate applied to the topsurface of the piece of cardstock; and an overwrap materialcircumscribing the three-dimensional object and the cardstock, theoverwrap material being in sealing relation with the laminate proximateto the first and second side edges to prevent lateral movement of thethree-dimensional object toward the side edges of the cardstock.
 2. Theinvention as in claim 1 wherein the laminate extends the lengthwisedimension of the cardstock.
 3. The invention as in claim 2 wherein theoverwrap material is heat-applied to the laminate.
 4. The invention asin claim 1 wherein the overwrap material is heat-sealed proximate theends of the cardstock to provide a relatively flat transverse bandsurface.
 5. The invention as in claim 4 wherein the relatively flattransverse band surface interconnects the insert with a second insertprovided in a continuous web, the transverse band including aperforation formed therein.
 6. The invention as in claim 1 wherein thelaminate is fabricated of an olefin-based thermo-sealable material. 7.The continuous web of a plurality of three-dimensional inserts adaptedfor handling by automated packaging apparatus, each insert in the webcomprising: a three-dimensional object; a piece of cardstock including atop surface, first and second ends, and first and second side edges; alaminate applied to the top surface of the cardstock; and an overwrapmaterial in surrounding relation to the three-dimensional object and tothe cardstock, the overwrap material being in heat-sealing engagementwith the laminate proximate to the first and second side edges topresent opposed, relatively flat side surface engage-able with thepackaging apparatus.
 8. The invention as in claim 7 wherein the laminateis a thermo-sealable olefin-based material.
 9. The invention as in claim8 wherein the overwrap material is heat-sealed proximate to the ends ofthe cardstock to provide a relatively flat transverse band connectingone insert in the web with a succeeding insert in the web.
 10. Theinvention as in claim 9 wherein the transverse band has a weakenedportion formed therein.
 11. The invention as in claim 10 wherein theweakened portion is a perforation.
 12. An insert comprising: athree-dimensional object; a support piece having a top surface, firstand second ends, and first and second side edges; and a flexibleoverwrap material surrounding and enclosing the three-dimensional objectand the support piece, the overwrap material being sealed to the topsurface of the support piece proximate to the first and second sideedges; and a sealable coating applied to at least a portion of the topsurface of the support piece.
 13. The insert as in claim 12 wherein thecoating is applied to at least the portion of the top surface proximatethe first and second side edges.
 14. The insert as in claim 13 whereinthe coating is applied only proximate the side edges.
 15. The insert asin claim 14 wherein the coating extends the lengthwise dimension of thesupport piece.
 16. The insert as in claim 12 wherein the coating isapplied to only the periphery of the top surface of the support piece.17. The insert as in claim 12 wherein the coating is applied tosubstantially all of the top surface of the support piece.
 18. Theinsert as in claim 12 wherein the coating comprises an olefin-basedthermosealable material.
 19. The insert as in claim 12 wherein thesupport piece is chosen from the group consisting of cardboard andcardstock.
 20. The insert as in claim 12 wherein the flexible overwrapmaterial is heat-sealed to the support piece via the coating.
 21. Theinsert as in claim 12 wherein the flexible overwrap material is sealedto itself so as to provide a relatively-flat, transverse band surfacedefining one end of the insert.
 22. The insert as in any one of claims12-21 wherein the flexible overwrap material is sealed to itself so asto provide two relatively-flat, transverse band surfaces defining eachof the ends of the insert.
 23. The insert as in claim 22 wherein one ofthe relatively-flat, transverse band surfaces interconnects the insertwith a second such insert by one of its relatively-flat, transverse bandsurfaces to form a connection band.
 24. A plurality of inserts as inclaim 23 interconnected as a continuous web.
 25. The insert as in claim23 wherein the connection band includes a weakened portion formedtherein.
 26. A plurality of inserts as in claim 25 interconnected as acontinuous web.
 27. The insert as in claim 25 wherein the weakenedportion includes a perforation.
 28. A plurality of inserts as in claim27 interconnected as a continuous web.
 29. A continuous web of aplurality of inserts, each insert in the web comprising: athree-dimensional object; a support piece having a top surface, firstand second ends, and first and second side edges; and a flexibleoverwrap material surrounding and enclosing the three-dimensional objectand the support piece, the overwrap material being sealed to the topsurface of the support piece proximate to the first and second sideedges; and a sealable coating applied to at least a portion of the topsurface of the support piece.
 30. The continuous web as in claim 29wherein the coating is applied to at least the portion of the topsurface proximate the first and second side edges.
 31. The continuousweb as in claim 30 wherein the coating is applied only proximate theside edges.
 32. The continuous web as in claim 31 wherein the coatingextends the lengthwise dimension of the support piece.
 33. Thecontinuous web as in claim 29 wherein the coating is applied only to theperiphery of the top surface of the support piece.
 34. The continuousweb as in claim 29 wherein the coating is applied to substantially allof the top surface.
 35. The continuous web as in claim 29 wherein thecoating comprises an olefin-based thermo-sealable material.
 36. Thecontinuous web as in claim 29 wherein the support piece is chosen fromthe group consisting of cardboard and cardstock.
 37. The continuous webas in claim 29 wherein the flexible overwrap is heat-sealed to thesupport piece via the coating.
 38. The continuous web as in any one ofclaims 29-37 wherein the flexible overwrap material is sealed to itselfso as to provide two relatively-flat, transverse band surfaces definingeach of the ends of each of the inserts.
 39. The continuous web as inclaim 38 wherein one of the relatively-flat, transverse band surfacesinterconnects the insert with a second such insert by one of itsrelatively-flat transverse band surfaces to form a connection band. 40.The continuous web as in claim 39 wherein the connection band includes aweakened portion formed therein.
 41. The continuous web as in claim 40wherein the weakened portion includes a perforation.
 42. An insertadapted for use in conjunction with packaging apparatus comprising: athree-dimensional object; a substrate having a top surface, first andsecond ends, and first and second side edges; and an overwrap materialcircumscribing the three-dimensional object and the substrate, theoverwrap material being in sealing relation with the top surface of thesubstrate proximate to the first and second side edges to inhibitlateral movement of the three-dimensional object toward the side edgesof the substrate; and wherein a sealable coating is applied to at leasta portion of the top surface of the substrate.
 43. The insert as inclaim 42 wherein the coating extends the lengthwise dimension of thesubstrate.
 44. The insert as in claim 42 or 43 wherein the overwrapmaterial is heat-sealed to the substrate.
 45. The insert as in claim 42or 43 wherein the overwrap material is heat-sealed proximate the ends ofthe substrate to provide a relatively flat transverse band surface. 46.The insert as in claim 45 wherein said relatively-flat, transverse bandsurface interconnects the insert with a second insert.
 47. The insert asin claim 46 wherein the transverse band includes a weakened portionformed therein.
 48. The insert as in claim 47 wherein the weakenedportion includes a perforation.
 49. The insert as in claim 42 whereinthe coating comprises an olefin-based thermo-sealable material.
 50. Theinsert as in claim 42 wherein the coating is applied to only theperiphery of the substrate.
 51. The insert as in claim 42 wherein thecoating is applied only proximate the side edges.
 52. The insert as inclaim 42 wherein the coating is applied to substantially all of the topsurface.
 53. A continuous web of a plurality of three-dimensionalinserts, each insert in the web comprising: a three-dimensional object;a substrate including a top surface, first and second ends, and firstand second side edges; and an overwrap material in surrounding relationto the three-dimensional object and to the substrate, the overwrapmaterial being in engagement with the top surface of the substrateproximate to the first and second side edges; and wherein the substratehas a coating applied to at least a portion of its top surface.
 54. Thecontinuous web as in claim 53 wherein the coating is applied to only theperiphery of the substrate.
 55. The continuous web as in claim 53wherein the coating is applied only proximate the side edges.
 56. Thecontinuous web as in claim 53 wherein the coating is applied tosubstantially all of the top surface.
 57. The continuous web as in claim53 wherein the coating comprises a thermo-sealable olefin-basedmaterial.
 58. The continuous web as in one of claims 53-57 wherein theoverwrap material is heat-sealed proximate to the ends of the substrateto provide a relatively flat transverse band connecting one insert inthe web with a succeeding insert in the web.
 59. The continuous web asin claim 58 wherein the transverse band has a weakened portion formedtherein.
 60. The continuous web as in claim 59 wherein the weakenedportion includes a perforation.